Beaded opening in sheet metal framing member

ABSTRACT

A punch ( 42 ) is used to form a circular opening ( 46 ) in the web ( 28 ) of a framing member ( 26 ). A first tool ( 50 ) is provided having a head ( 56 ) with a first end and a circular cross section that increases in diameter as it extends from the first end axially inwardly of the tool ( 50 ). The first end of this head ( 56 ) is inserted into the circular opening ( 46 ) and the tool ( 50 ) is rotated and is moved axially into the opening ( 46 ), for stretching the metal surrounding the opening ( 46 ) and forming a flare ( 60 ) that surrounds the opening ( 46 ). A second tool ( 62 ) is provided having a head ( 68 ) with a first end and a circular cross section that increases in diameter from the first end axially inwardly of the tool ( 62 ). The first end of this tool is inserted into the flare ( 60 ) from the second side of the web ( 28 ). The tool ( 62 ) is rotated and moved axially so that the head ( 68 ) will further stretch the metal surrounding the opening and form the flare ( 60 ) into a bead ( 60 ) that surrounds and become the periphery of the opening ( 46 ).

TECHNICAL FIELD

This invention relates to sheet metal framing members, such as sheetmetal studs or the like. More particularly, it relates to the provisionof a beaded opening in the framing member for receiving an elongatedarticle, e.g. an electrical cable, metal or plastic conduit or the like.

BACKGROUND OF THE INVENTION

Framing walls are typically constructed from a plurality of horizontallyspaced apart vertically extending studs that are connected at theirupper and lower ends to horizontally extending members termed “tracks”.Some framing is constructed from wood members and other is constructedfrom sheet metal members. When wood members are used, it is commonpractice to drill a series of holes in the studs for receiving anelectrical cable, water pipe, etc. that must extend through the interiorof the wall of which the framing is a part. When sheet metal framemembers are used for the framing, it has been the practice to stampholes in the webs of the studs and extend the electrical cable,conduits, etc. through these holes. A problem experienced when thismethod is used is that the stamped openings have sharp edges that cutthe electrical cable and/or conduit that is inserted through theopenings. A principal object of the present invention is to eliminatethis problem by eliminating the sharp edges at the periphery of theopenings.

BRIEF SUMMARY OF THE INVENTION

The method of the invention comprises forming an opening in the web of aframing member then introducing a framing tool into the opening from afirst side of the framing member and using said tool the metalimmediately surrounding the opening, causing the flare to curve convexlyfrom the first side of the framing member inwardly into the opening.Next, a forming tool is introduced into the flare from the second sideof the framing member and used to reverse curl the flare and form itinto a bead at the periphery of the opening. The bead is formed topresent a convexly rounded inner surface in the opening positioned to becontacted by any object inserted into and through the opening.

In one embodiment, the framing member is positioned on a support memberthat includes a punch-receiving opening. The punch is moved against theweb on the side of the web opposite the support member, in alignmentwith the opening in the support member. Then, the punch is extended topunch an opening through the web of the frame member. After forming theopening the punch moves through the punch opening in the support member.

In preferred form, the frame member has a channel cross section composedof the web and two flanges. The web extends between and interconnectsthe two flanges. The punch is introduced against the side of the web onwhich the flanges are located.

In preferred form, the first forming tool is inserted into the openingfrom the side of the web on which the flanges are located. The secondforming tool is inserted into the flare from the side of the framingmember opposite the flanges.

In preferred form, the opening formed in the web is a circular opening.The tool that is used to form the flare has a head with a first end anda circular cross sectional shape that increases in diameter from thefirst end as it extends axially inwardly of the tool. The tool thatforms the bead has a head with the first end a circular cross sectionthat increases in diameter as it extends from the first end axially ofthe tool. This flare forming tool is rotated as it is moved axially intothe opening to form the flare. The bead forming tool is rotated as it ispushed axially into the flare to form the bead.

Other objects, advantages and features of the invention will becomeapparent from the description of the best mode set forth below, from thedrawings, from the claims and from the principles that are embodied inthe specific structures that are illustrated and described.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Like reference numerals are used to designate like parts throughout theseveral views of the drawing, and:

FIG. 1 is a fragmentary pictorial view of a region of a sheet metal studthat includes a prior art opening in which an electrical cable isreceived;

FIG. 2 is a fragmentary elevational view of the stud and the electricalcable shown in FIG. 1, taken perpendicular to the web of the stud, withthe cable shown in section;

FIG. 3 is a fragmentary sectional view taken substantially along line3-3 of FIG. 2;

FIG. 4 is a sectional view of a sheet metal stud with its web on asupport showing a circular punch moving through the web and an openingin the support member;

FIG. 5 is a view like FIG. 4, but showing a forming tool being rotatedand moved axially into the punched opening in the web so as to flare theopening and create a flared lip that surrounds the opening;

FIG. 6 is a view like FIG. 5, showing a second tool being rotated andmoved axially through the flared opening from the opposite side of thestud, for reversing the curl of the flare and forming a bead at theperiphery of the opening;

FIG. 7 is a sectional view taken through the stud at the location of abeaded opening, such view including a broken line showing of anelectrical cable or other elongated member extending through the beadedopening; and

FIG. 8 is a fragmentary pictorial view of a portion of a stud thatincludes two beaded openings, such view showing an electrical cableextending through one of the beaded openings.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

U.S. Pat. No. 5,127,203, granted Jul. 7, 1992, to Robert F. Paquette,and U.S. Pat. No. 6,854,237, granted Feb. 15, 2005, to Matt F.Surowiecki, show framing walls composed of upper and lower, horizontal,channel members, termed “tracks”, and spaced apart, vertical studsextending between the upper and lower channel members. Both of thesepatents disclose wallboard sheeting secured to the opposite sides of theframing wall.

Referring to FIGS. 1-3 of the drawing, sheet metal studs 10 comprise aweb 12 that extends between and interconnects one set of edges of a pairof flanges 14, 16. The other set of edges of the flanges 14, 16 areconnected to lips 18, 20. The web 12 and lips 18, 20 are substantiallyparallel with each other and are substantially perpendicular to theflanges 14, 16. Thus, the flanges 14, 16 are substantially parallel toeach other and are substantially perpendicular to the web 12 and thelips 18, 20. It is a known practice to form openings 22 in the webs ofthe studs 10 for receiving and accommodating an electrical cable 24 orsome other elongated member (e.g. metal or plastic tubing) which must behoused in the framing wall. FIGS. 1-3 show a prior art opening 22 whichis formed by a punch. A problem with this type of opening 22 is that thepunching process leaves sharp edges at the edges of the opening 22, oneof which is designated 26. The electrical cable 24 is fed through theopenings 22 which are usually at the same elevation in all of the studs10. As the electrical cable 24 or other object is being pulled throughthe stamped openings 22, its surface rides on the sharp edges 22 of theopenings 22. Quite often the sharp edges 24 cut into and damage theelectrical cable 24 or other object.

Referring to FIG. 4, a stud 26 is shown to comprise a web 28, a pair offlanges 32, 34 and a pair of lips 36, 38. The web 28 extends between andinterconnects common edges of the flanges 32, 34. The opposite edges ofthe flanges 32, 34 are connected to lips 36, 38. The web 28 and the lips36, 38 are substantially parallel to each other and substantiallyperpendicular to the flanges 32, 34. The flanges 32, 34 aresubstantially parallel to each other and substantially perpendicular tothe web 28 and the lips 36, 38. As shown by FIGS. 4-6, this gives theframing member 26 a lipped channel cross sectional shape.

FIG. 4 shows the framing member 26 with its web against and supported bya support member 40. A suitable tool or punch 42 is moved against theweb 28 in alignment with a punch-receiving opening 44 formed in thissupport member 40. The punch is used to stamp or punch a circularopening 46 in the web 28 by removing a disc shaped piece 48 from the web28. Next, a suitable tool 50 is moved into the opening 46 from the openside of the member 26. This tool 50 is used to flare the opening 46. Byway of example, the tool 50 is a rotatable forming member 52 thatincludes a shaft 54 that is connected to a rotary driver (not shown).Tool 52 also includes a forming head 56 that has a forming surface 58shaped to flare the material 60 surrounding the opening 46 as the toolis rotated and moved into the opening. After the flare 60 is formed, asecond tool 62 is introduced into the flared opening 46, from theopposite side of the member 26. By way of example, this tool 62 may be arotary forming tool 64 having a shaft 66 that is attached to a rotarydriver (not shown). Tool 62 includes a shaping head 68 which is shapedto curl the flared portion 60 of the web 28 so as to form it into anannular bead 60′ that surrounds the periphery of the opening 46. Thebead 60′ starts curling as it extends inwardly of the opening from web28. The curling continues through the opening 46 and beyond the opening46 so that the bead 60′ is substantially torus in shape. It is notnecessary that the bead 60′ be curled as much as is illustrated in FIGS.7 and 8. It is only necessary that it be curled to the extent that thewire cable 24 or other elongated object 24 will contact a roundedsurface at the periphery of the opening 46. A sharp edged periphery forthe opening 46 is eliminated.

The illustrated embodiments are only examples of the present inventionand, therefore, are non-limitive. It is to be understood that manychanges in the particular structure, materials and features that aredisclosed may by made without departing from the spirit and scope of theinvention. For example, the framing member may be punched and the flareformed and then the bead formed by the use of successive tools which aremounted on rollers through which the sheet metal member passes. Also,the bead may be formed on the inside of the web rather than on theoutside, as illustrated. Therefore, it is my intention that my patentrights not be limited by the particular embodiments that are illustratedand described herein, but rather are to be determined by the followingclaims, interpreted according to accepted doctrines of patent claiminterpretation, including use of the doctrine of equivalents.

1. A method of forming a beaded opening in a frame member having a web,comprising: forming an opening in the web of the framing member;introducing a forming tool into the opening from a first side of theframing member, and using said tool to flare the metal immediatelysurround the opening; causing said flare curving convexly from the firstside of the framing member inwardly into the opening; introducing aforming tool into the flare from the second side of the framing memberand using said forming tool to reverse curl the flare and form it into abead that becomes the periphery of the opening; and causing said beadpresenting a convexly rounded inner surface in the opening positioned tobe contacted by any object that is inserted into and through theopening.
 2. The method of claim 1, comprising supporting the framingmember on a support member that includes a punch receiving opening;bringing a punch against the web on the side of the web opposite thesupport member; positioning the punch in alignment with the opening inthe support member; and extending the punch to punch an opening throughthe web of the framing member, moving the punch through the punchopening in this support member.
 3. The method of claim 1, comprisingproviding a frame member having a channel cross section composed of theweb and two flanges, said web extending between and interconnecting thetwo flanges, and introducing the punch against the side of the web onwhich the flanges are located.
 4. The method of claim 3, comprisingintroducing the first framing tool into the opening from the side of theweb on which the flanges are located.
 5. The method of claim 4,comprising introducing the second forming tool into the flare from theside of the framing member opposite the flanges.
 6. The method of claim1, comprising forming a circular opening in the web and providing a toolwith a head having a first end insertable of the circular opening and acircular cross section throughout its length which increases in diameteras it extends from the first end axially inwardly of the tool head, androtating said tool and moving it axially into the circular opening forspin forming the flanges that surrounds the opening.
 7. The method ofclaim 6, comprising providing a tool with a head having a first end andcircular cross section increasing in diameter from the first end axiallyinwardly of the tool, and inserting the first end of such tool into theflared opening from the second side of the framing member and rotatingsaid tool and moving it axially inwardly to form the flare into a beadthat becomes the periphery of the opening.
 8. A framing member having achannel shape cross section formed by a pair of spaced apart flanges anda web that extends between and interconnects common edges of theflanges; at least one beaded opening formed in the web of the framingmember, said beaded opening being circular at its center and having abead at its periphery; said bead curving convexly as it extends from oneside of the web into the opening and then curving convexly from thecenter of the opening as it continues to extend away from the web,whereby the beaded opening presents a rounded convex surface leadinginto the opening followed by a rounded convex surface leading out fromthe opening.
 9. The framing member of claim 7, where in the bead is onthe side of the web that is opposite the spaced apart flanges.
 10. Theframing member of claim 7, comprising a plurality of axially spacedapart beaded openings formed in the web of the framing member.
 11. Theframing member of claim 9, where in the beads are on the side of the webthat is opposite the spaced apart flanges.